Flocked thermoplastic fabric hat



Jam.A 30, 1968 s. G. HOFFMAN FLOCKED THERMOPLASTIC FABRIC HAT FIG -l vavnnvxmvzsamenvalt FIG-'5 INVENTOR.

TmvLEjcs. Horrr'wu dwcud AT1-ORN Ef United States Patent O 3,365,727 FLCKED THERMPLASTIC FABRIC HAT Stanley G. Holfman, Norwalk, Conn., assignor to Hat Corporation of America, Norwalk, Conn., a corporation of Delaware Filed Nov. 12, 1963, Ser. No. 322,604 12 Claims. (Cl. 2-192) This invention relates to hats made of moldable thermoplastic fabrics having ocking adhesively secured to said fabrics prior to the molding operation. More particulmly, this invention contemplates the manufacture of a one-piece molded hat body made out of a ilat thermoplastic flocked starting material to produce a hat which will have the look, feel and wearing qualities of a fine natural felt hat.

Fine quality felt hats are presently being made of blends of bers hom fur bearing animals such as rabbits, muskrat, beaver and mink. These furs are becoming more costly and difficult to obtain. For example, England, which used to export 200,000 pounds of rabbit fur annually, now does not export any fur; Australia, which eX- ported as recently as 1958 over 600,000 pounds of fur, only had 260,000 pounds 1962. This situation has been brought on by economic changes within these countries with strong de-emphasis on fur production in favor of farming in England and Wool in Australia. In fact, both of these countries consider the rabbit a pest and drastic measures are being undertaken to obliterate them. In addition, as the population of the world grows larger and rural areas become cities, the natural habitat of muskrats and beaver is disappearing With the result that fur from these animals is also becoming scarce.

It is, therefore, an object of this invention to make a quality hat of a moldable flocked fabric which will have the appearance, feel and wearing qualities equal to or superior to a fur felt hat.

It is a further object of this invention to make a synthetic hat out of a fiat starting material which can be stretch molded into a one-piece hat body having a unitary crown and brim.

It is also an object of this invention to provide a synthetic hat which will be capable of being washed, and which will retain its line appearance and resume its proper shape after washing, and which may be truly called a wash and wear hat.

t is a special object of this invention to provide a suitable thermoplastic fabric for the hat body and a suitable adhesive for securing the flock to the thermoplastic fabric to form the at body material which can then be stretch molded into the hat body.

Further objects and advantages of the invention will appear in the specification hereinbelow. 'Ihese objects and advantages are achieved with the invention as illustrated in the accompanying drawings in which:

FIG. 1 is a diagrammatic construction detail of a fabric;

FIG. 2 is a diagrammatic construction detail of another form of fabric;

FIG. 3 is a sectional view of a hat composite fabric;

FIG. 4 is a sectional view of another form of fiat composite fabric; Y

FIG. 5 is a sectional view of a hat body made of a material of the invention; and

FIG. 6 is an enlarged sectional detail taken between the lines 6 6 of FIG. 5.

It is well known in the art that hats can be made of moldable fabrics of thermoplastic synthetic fibers, and there are patents describing this art; for example: United States Letters Patent No. 2,926,358 issued on March 1, 1960, on application of S. G. Hoffman et al.

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It is equally well known that ock prepared of such synthetic and natural fibers as nylon, Daeron, Orlon, rayon, cotton, wool, fur and other materials, can be applied and adhesively secured to various synthetic and natural textiles in the Imanufacture of articles such as shoe uppers, simulated leather jackets and coats, handbags, vests, dresses and similar articles.

In the manufacture of a hat in accordance with the invention, it is desirable to provide a fiat starting material which may be stretch molded by the application of heat, and Vmolding in a proper apparatus (in accordance with the patent set forth above) from said ilat starting material to a properly shaped hat body including the brim and crown portions. ln hat manufacture of this nature, a deep stretch or draw is required to 4mold the hat crown. By stretch molding, I mean simultaneously stretching and molding the at starting material in the form such as shown in FIG. 4 into a hat body in the form such as shown in FIG. 5 having brim and crown portions.

I have found that the usual thermoplastic fabrics used in the manufacture of the above mentioned articles of apparel are not suitable for use in the manufacture of felt type hats by the stretch molding process. Thus, it is necessary to provide a woven thermoplastic material having a specific fabric constructional weave pattern which would permit obtaining the deep draw required to mold the hat crown, but also to retain a dense surface with a minimum of porosity after stretch molding. A suitable adhesive must also be provided, for applying the flock to the thermoplastic material, which would be capable of being heated and molded during the manufacture of the hat so that the bond between the thermoplastic body material and the flock would not be impaired in such manufacture.

An adhesive for such a purpose must possess the following characteristics: Y

(l) I-t should be a high temperature thermoplastic;

(2) It must fiow during the simultaneous heating, stretching and molding operations without disrupting the adhesive ybond between the fabric and flock;

(3) It must not stiften or harden after being heated or upon aging of the ocked fabric;

(4) It should withstand abrasion in normal wear;

(5 It must be insoluble in water;

(6) It must not be affected by solvents used in dry cleaning such as naphtha and carbon tetrachloride;

(7) It must not be tacky during the molding operation;

(8) It should be odorless after molding; and

(9) The adhesion bond must be resilient.

The plastic fabric out of which the hat body is made is woven from -a thermoplastic yarn of vinyl chloride-acrylonitrile which is well known and sold under the trademark Dynel by the Union Carbide Corp., or from a modified acrylic fiber such `as the type sold under the trademark Verel by the Eastman Kodak Company. The thermoplastic material of the hat body may also be woven from a yarn of modified vinyl chloride or any other suitable yarn for weaving a thermoplastic material.

Fabrics having either a 3/ 2 sheen weave as illustrated in FIG. 1 of the drawings or the 4/1 sheen weave as illustrated in FIG. 2 of the drawings have been developed lfor making a hat in `accordance with the invention. For example, Dynel yarn, 3 denier, 11/2" staple with 21/1s cotton count, having at least 80 ends and at least 58 picks in the greige off the loom, will have the proper neness of Weave required to .permit the material to be stretch molded into the crown of the hat in accordance with the invention.

While satisfactory hat bodies will be produced from materials such as those illustrated in FIGS. 1 and 2 of the drawings, in which there are at least 80 ends and 58 picks, it is preferred to have a body material in which there are at least 100 ends and 72 picks. It is considered that the foregoing gives sutiicient data to one skilled in the art to reproduce the fabrics required as a starting material for the hat body.

The adhesive 12, 18 or 20 is applied to the fabric 10 or 16 by means of a doctor blade which evenly spreads a thin uniform layer of adhesive onto the fabric, and ock material 14, 22 or 24 is then sprinkled onto the adhesive fabric and caused to adhere to the surface. The tiocked fabric as shown in FIG. 3 or FIG. 4 of the drawings is then dryed to establish a strong bond between the fabric and flock. Excess flock which has not adhered to the fabric is `removed by vacuuming. In the preparation of my fiocked fabric, I prefer to iiock both sides of the fabric as in FIG. 4. Only one side of the fabric, as in FIG. 3, can be flocked and two pieces of such a flocked fabric can be combined back to back so that there would be a ocked surface on either side of the combined fabric, and would result in a heavier, thicker fabric than if both Sides of a single fabric were flocked, and the resultant molded hat from such a fabric would naturally be heavier and thicker. Y

The adhesive 12, 13 or 20 necessary for the invention, and which will have the qualities outlined hereinabove, comprises vinyl chloride-acetate copolymer resin, acrylonitrile-butadiene rubber; solvents, anti-oxidants, residual chlorine scavengers, and heat and light stabilizers. The vinyl copolymer resin is identified as vinyl chloride-acetate copolymer resin, and the acrylonitrile rubber is identified as acrylonitrile-butadiene rubber. These elements of the adhesive compound are the working elements that actually combine the tiock to the material. The solvents, the anti-oxidants, the -residual chlorine scavengers and the heat and light stabilizers act as a carrier and for the other purposes indicated respectively, such as to prevent oxidation and to prevent such other chemical reaction by reason of presence of chlorine or heat or light which would ordinarily cause the adhesive otherwise to become hard and brittle. I have found that solvents such as methyl ethyl ketone, xylene, ethyl acetate, di-acetone, isopropylacetone and toluene and ethyl alcohol may be used. Of course, other appropriate solvents may also be used. An anti-oxidant such as alkylated phenol may be used, an

- epoxy resin may be used as the residual chlorine scavenger, and organo tin complex may be used as the heat and light stabilizer. 1f desirable, l may include a plasticizer for the Dynel such as a mixture of N-ethyl ortho and para toluene sulfonamides.

given in .percent by weight.

EXAMPLE 1 Di-acetone 16.72 Xylene 39.07 Isopropyl-acetone 14.61 Vinyl chloride-acetate copolymer resin 9.70

Acrylonitrile-butadiene rubber 16.81 Mixture of N-ethyl ortho and para toluent sulfonamides 1.45 Alkylated phenol 0.48 Epoxy resin 0.97 Organo tin complex 0.19

'rotar 100.00

4 EXAMPLE 2 Polyglycolterephthalate resin 39.22 Ethyl alcohol 2.94 Di-acetone 5.88

'isopropyl-acetone 51.96

Total 100.00

After the Hocking has been bonded to the fabric made of thermoplastic synthetic fibers, by la thermoplastic adhesive as described hereinabove, it becomes a composite flat continuous piece of material (as in FlG. 3 or FiG. 4) from which a hat may be stretch molded in accordance with apparatus and method as shown in Hoffman Patent No. 2,926,358, or by any other stretch molding process which may be known to the art.

It has been found that a satisfactory one-piece hat body 26 having a crown portion 28 and a brim portion 30 may be made in accordance with the invention by heating the composite material within a range of 250 to 350 F. for from 60 to 120 seconds, then immediately placing the heated composite material in an unheated apparatus, and then stretch molding and allowing the composite material to cool and set in the mold.

While the range of heat and time has been given hereinabove, the preferred heat is 300 F. for a period of 90 seconds when using a Dynel material of either 3/ 2 or 4/ 1 sheen weave made of a yarn of 3 denier, 11/2 staple with 21/1s cotton count, the resulting fabric in the greige off the loom having at least 100 ends and at least 72 picks. After the cooled and set hat body is removed from the mold, all excess material may be cut off the brim 30, and the body may then be placed through theV hat finishing operations such as trimming, edge binding, edge welding, lining, banding and any other of the usual hat finishing processes ordinarily found in the art of finishing fine fur felt hats.

While the invention has been described in its preferred form, there are other forms which it may take Without departing from the spirit and scope of the invention, and it is, therefore, desired to have protection for all forms coming within the claims hereinbelow.

Wherefore I claim: Y

1. As a product of manufacture, a stretch molded hat body made from a flat composite material comprising: a thermoplastic synthetic fabric having a 3/2 sheen Weave, a 3 denier yarn, and a 11/2 staple having 21/1s cotton count, the resulting fabric in the greige off the loom having at least ends and at least 58 picks; a layer of adhesive comprising di-acetone, xylene, isopropyl-acetone, vinyl chloride-acetate copolymer resin, acrylonitrile-butadiene rubber, mixture of N-ethyl ortho and para toluene sulfonamides, alkylated phenol, epoxy resin and organo tin complex; and a plurality of bits of flock; said iiock being adhesively bonded to said thermoplastic synthetic fabric; whereby when said flat composite material is heated and stretch molded into a hat body, said material Will stretch and mold as a unitary composite material with the bonded ock, the adhesive and the thermoplastic fabric being maintained in proper relationship to each other Within the composite material.

2. The hat body as defined in claim 1, in which the Woven thermoplastic synthetic fabric is a woven thermoplastic yarn comprising vinyl chloride acrylonitrile.

3. The hat body as defined in claim 2, in which the said ingredients for the-said adhesive are comprised substantially in the following amounts given in percent by Weight: di-acetone 17%, xylene 39%, isopropyl-acetone 15%, vinyl chloride-acetate copolymer resin 10%, acrylonitrile-butadieue rubber 17%, mixture of N-ethyl ortho and para toluene sulfonamides 1.5%, alkylated phenol .05%, epoxy resin .1%, organo tin complex .02%.

4. As a product of manufacture, a stretch molded hat body made from a fiat composite material comprising: a thermoplastic synthetic fabric having a 4/1 sheen weave,

a 3 denier yarn, and a 11/2 staple having 21/ ls cotton count, the resulting fabric in the greige off the loom having at least 80 ends and at least 58 picks; a layer of adhesive comprising di-acetone, Xylene, isopropyl-acetone, vinyl chloride-acetate copolymer resin, acrylonitrile-butadiene rubber, mixture of N-ethyl ortho and para toluene sulfonamides, alkylated phenol, epoxy resin and organo tin complex; and a plurality of bits of flock; said ock being adhesively bonded to said thermoplastic synthetic fabric; whereby when said ilat composite material is heated and stretch molded into a hat body, said material will stretch and mold as a unitary composite material with the bonded flock, the adhesive and the thermoplastic fabric being maintained in proper relationship to each other within the composite material.

5. The hat body as defined in claim 4, in which the Woven thermoplastic synthetic fabric is a woven thermoplastic yarn comprising vinyl chloride acrylonitrile.

6. The hat body as defined in claim 5, in which the said ingredients for the said adhesive are comprised substantially in the following amounts given in percent by Weight: di-acetone 17%, Xylene 39%, isopropyl-acetone 15%, vinyl chloride-acetate copolymer resin acrylonitrile-butadiene rubber 17%, mixture of N-ethyl ortho and para toluene sulfonamides 1.5%, alkylated phenol .05%, epoxy resin .l%, organo tin complex .02%.

7. As a product of manufacture, a stretch molded hat body made from a flat composite material comprising: a thermoplastic synthetic fabric having a 3/ 2 sheen Weave, a 3 denier yarn, and a 11/2" staple having 21/ls cotton count, the resulting fabric in the greige off the loom having at least 80 ends and at least 58 picks; a layer of adhesive comprising polyglycolterephthalate resin, ethyl alcohol, di-acetone and isopropyl-acetone; and a plurality of bits of flock; said ock being adhesively bonded to said thermoplastic synthetic fabric; whereby when said iiat composite material is heated and stretch molded into a hat body, said material Will stretch and mold as a unitary composite material with the bonded flock, the adhesive and the thermoplastic fabric being maintained in proper relationship to each other within the composite material.

8. The hat body as defined in claim 7, in which the Woven thermoplastic synthetic fabric is a woven thermoplastic yarn comprising vinyl chloride acrylonitrile.

9. The hat body as defined in claim 8, in which the said ingredients for the said adhesive are comprised substantially in the following amounts given in percent by weight: polyglycolterephthalate resin 39%, ethyl alcohol 3%, di-acetone 6%, isopropyl-acetone 52%.

10. As a product of manufacture, a stretch molded hat body made from a at composite material comprising: a thermoplastic synthetic fabric having a 4/1 sheen weave, a 3 denier yarn, and a 11/2" staple having 21/ ls cotton count, the resulting fabric in the greige off the loom having at least ends and at least 58 picks; a layer of adhesive comprising polyglycolterephthalate resin, ethyl alcohol, di-acetone and isopropyl-acetone; and a plurality of bits of flock; said iiock being adhesively bonded to said thermoplastic synthetic fabric; whereby when said at composite material is heated and stretch molded into a hat body, said material will stretch and mold as a unitary composite material with the bonded flock, the adhesive and the thermoplastic fabric being maintained in proper relationship to each other Within the composite material.

11. The hat body as defined in claim it), in which the woven thermoplastic synthetic fabric is a Woven thermoplastic yarn comprising vinyl `chloride acrylonitrile.

12. The hat body as defined in claim 11, in which the said ingredients `for the said adhesive are comprised substantially in the following amounts given in percent by Weight: polyglycolterephthalate, resin 39%, ethyl alcohol 3%, di-acetone 6%, isopropyl-acetone 52%.

References Cited UNITED STATES PATENTS 1,408,871 3/1922 Enos 161-64 2,156,238 4/1939 Frankmann et al. 2-192 2,688,577 9/1954 Fischer 161-64 2,912,398 11/1959 Johnson et al 260-33 2,926,358 3/ 1960 Hoffmann et al. 2 193 3,067,085 12/ 1962 Limperos 260-32 'JORDAN FRANKLIN, Primary Examiner.

G. H. KRIZMANICH, Assistant Examiner. 

1. AS A PRODUCT OF MANUFACTURE, A STRETCH MOLDED HAT BODY MADE FROM A FLAT COMPOSITE MATERIAL COMPRISING: A THERMOPLASTIC SYNTHETIC FABRIC HAVING A 3/2 SHEEN WEAVE, A 3 DENIER YARN, AND A 1 1/2" STAPLE HAVING 21/1''S COTTON COUNT, THE RESULTING FABRIC IN THE GRIEGE OFF THE LOOM HAVING AT LEAST 80 ENDS AND AT LEAST 58 PICKS; A LAYER OF ADHESIVE COMPRISING DI-ACETONE, XYLENE, ISOPROPYL-ACETONE, VINYL CHLORIDE-ACETATE COPOLYMER RESIN, ACRYLONITRILE-BUTADIENE RUBBER, MIXTURE OF N-ETHYL ORTHO AND PARA TOLUENE SULFONAMIDES, ALKYLATED PHENOL, EPOXY RESIN AND ORGANO TIN COMPLEX; AND A PLURALITY OF BITS OF FLOCK; SAID FLOCK BEING ADHESIVELY BONDED TO SAID THERMOPLASTIC SYNTHETIC FABRIC; WHEREBY WHEN SAID FLAT COMPOSITE MATERIAL IS HEATED AND STRETCH MOLDED INTO A HAT BODY, SAID MATERIAL WILL STRETCH AND MOLD AS A UNITARY COMPOSITE MATERIAL WITH THE BONDED FLOCK, THE ADHESIVE AND THE THERMOPLASTIC FABRIC BEING MAINTAINED IN PROPER RELATIONSHIP TO EACH OTHER WITHIN THE COMPOSITE MATERIAL. 